U.S. patent application number 11/982233 was filed with the patent office on 2008-08-07 for fan array fan section in air-handling systems.
Invention is credited to Lawrence G. Hopkins.
Application Number | 20080187433 11/982233 |
Document ID | / |
Family ID | 34841710 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080187433 |
Kind Code |
A1 |
Hopkins; Lawrence G. |
August 7, 2008 |
Fan array fan section in air-handling systems
Abstract
A fan array fan section in an air-handling system includes a
plurality of fan units arranged in a fan array and positioned
within an air-handling compartment. One preferred embodiment may
include an array controller programmed to operate the plurality of
fan units at peak efficiency. The plurality of fan units may be
arranged in a true array configuration, a spaced pattern array
configuration, a checker board array configuration, rows slightly
offset array configuration, columns slightly offset array
configuration, or a staggered array configuration.
Inventors: |
Hopkins; Lawrence G.;
(Portland, OR) |
Correspondence
Address: |
CHERNOFF, VILHAUER, MCCLUNG & STENZEL
1600 ODS TOWER, 601 SW SECOND AVENUE
PORTLAND
OR
97204-3157
US
|
Family ID: |
34841710 |
Appl. No.: |
11/982233 |
Filed: |
October 31, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11595212 |
Nov 9, 2006 |
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11982233 |
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10806775 |
Mar 22, 2004 |
7137775 |
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11595212 |
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PCT/US04/08578 |
Mar 19, 2004 |
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10806775 |
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60456413 |
Mar 20, 2003 |
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60554702 |
Mar 20, 2004 |
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Current U.S.
Class: |
415/51 ; 417/3;
417/426; 454/256 |
Current CPC
Class: |
F04D 27/004 20130101;
F04D 19/002 20130101; F24F 11/77 20180101; F04D 29/522 20130101;
F04D 25/166 20130101; F04D 27/0261 20130101; F05D 2270/023
20130101; F05D 2270/03 20130101; F24F 7/007 20130101; F04D 29/644
20130101; F05D 2270/3061 20130101; F24F 7/06 20130101; F24F 11/74
20180101; F04D 29/664 20130101; Y02B 30/70 20130101 |
Class at
Publication: |
415/51 ; 417/3;
417/426; 454/256 |
International
Class: |
F04D 27/00 20060101
F04D027/00; F04D 25/16 20060101 F04D025/16; F24F 7/007 20060101
F24F007/007; F24F 13/08 20060101 F24F013/08; F24F 11/00 20060101
F24F011/00 |
Claims
1-42. (canceled)
43. A system comprising: means for specifying at least one of a
plurality of user-health test functions responsive to an
interaction between a user and at least one advertiser-specified
attribute; and means for transmitting at least one output of the at
least one user-health test function related to the at least one
advertiser-specified attribute.
44. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
device-implemented application configured to present the at least
one advertiser-specified attribute.
45. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one alertness or attention test function responsive to the
interaction between the user and the at least one
advertiser-specified attribute.
46. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one memory test function responsive to the interaction
between the user and the at least one advertiser-specified
attribute.
47. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one speech or voice test function responsive to the
interaction between the user and the at least one
advertiser-specified attribute.
48. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one calculation test function responsive to the interaction
between the user and the at least one advertiser-specified
attribute.
49. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one neglect or construction test function responsive to the
interaction between the user and the at least one
advertiser-specified attribute.
50. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one task sequencing test function responsive to the
interaction between the user and the at least one
advertiser-specified attribute.
51. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one visual field test function responsive to the interaction
between the user and the at least one advertiser-specified
attribute.
52. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one pupil movement or eye movement test function responsive
to the interaction between the user and the at least one
advertiser-specified attribute.
53. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one face pattern test function responsive to the interaction
between the user and the at least one advertiser-specified
attribute.
54. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one hearing test function responsive to the interaction
between the user and the at least one advertiser-specified
attribute.
55. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one motor skill or body movement test function responsive to
the interaction between the user and the at least one
advertiser-specified attribute.
56. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to at least a keyboard-mediated interaction between the user and
the at least one advertiser-specified attribute.
57. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to at least a pointing device-mediated interaction between the user
and the at least one advertiser-specified attribute.
58. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to at least an imaging device-mediated interaction between the user
and the at least one advertiser-specified attribute.
59. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to at least an audio device-mediated interaction between the user
and the at least one advertiser-specified attribute.
60. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between the user and at least one
device-implemented game configured to present the at least one
advertiser-specified attribute.
61. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between the user and at least one
device-implemented security application configured to present the
at least one advertiser-specified attribute.
62. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between the user and at least one
device-implemented communication application configured to present
at least one advertiser-specified attribute.
63. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between the user and at least one
device-implemented productivity application configured to present
the at least one advertiser-specified attribute.
64. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to the interaction between the user and at least one
advertiser-specified color.
65. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to the interaction between the user and at least one
advertiser-specified textual display.
66. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to the interaction between the user and at least one
advertiser-specified design.
67. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one of a plurality of user-health test functions responsive
to the interaction between the user and at least one
advertiser-specified sound.
68. The system of claim 43 wherein the means for specifying at
least one of a plurality of user-health test functions responsive
to an interaction between a user and at least one
advertiser-specified attribute comprises: means for specifying at
least one user-health test function responsive to the interaction
between the user and at least one device-implemented application
configured to present at least one advertiser-specified brand.
69. The system of claim 43 wherein the means for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute
comprises: means for sending to at least one entity at least one
measure of the user's attention to the at least one
advertiser-specified attribute as the at least one output of the at
least one user-health test function related to the at least one
advertiser-specified attribute.
70. The system of claim 43 wherein the means for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute
comprises: means for sending to at least one entity at least one
measure of the user's pupil movements or eye movements relating to
the at least one advertiser-specified attribute as the at least one
output of the at least one user-health test function related to the
at least one advertiser-specified attribute.
71. The system of claim 43 wherein the means for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute
comprises: means for sending to at least one entity at least one
measure of the user's memory relating to the at least one
advertiser-specified attribute as the at least one output of the at
least one user-health test function related to the -at least one
advertiser-specified attribute.
72. The system of claim 43 wherein the means for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute
comprises: means for sending to at least one entity at least one
measure of the user's visual field relating to the at least one
advertiser-specified attribute as the at least one output of the at
least one user-health test function related to the at least one
advertiser-specified attribute.
73. The system of claim 43 wherein the means for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute
comprises: means for sending to at least one entity at least one
measure of the user's face pattern relating to the at least one
advertiser-specified attribute as the at least one output of the at
least one user-health test function related to the at least one
advertiser-specified attribute.
74. The system of claim 43 further comprising: means for receiving
an indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function.
75. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving a request from the at
least one entity for a subscription to at least a portion of the at
least one output of the at least one user-health test function.
76. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest from at least one of an advertiser, an advertising broker,
an advertising seller, a marketer, a merchant, or a host of
advertising as the at least one entity.
77. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest from a researcher as the at least one entity.
78. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest from at least one of an online game company, an internet
search company, a virtual world company, an online product vendor,
or a website host as the at least one entity.
79. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest from a law enforcement entity as the at least one
entity.
80. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest from a teammate as the at least one entity.
81. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest in at least one statistical characteristic of the at least
a portion of the at least one output of the at least one
user-health test function.
82. The system of claim 74 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving an indication of
interest in anonymized output of the at least a portion of the at
least one output of the at least one user-health test function.
83. The system of claim 43 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving compensation for
access to the at least one output of the at least one user-health
test function.
84. The system of claim 43 wherein the means for receiving an
indication of interest from at least one entity in at least a
portion of the at least one output of the at least one user-health
test function comprises: means for receiving at least one of a
payment or a micropayment for access to the at least one output of
the at least one user-health test function.
85. A computer program product comprising: a signal-bearing medium
bearing (a) one or more instructions for specifying at least one of
a plurality of user-health test functions responsive to an
interaction between a user and at least one advertiser-specified
attribute; and (b) one or more instructions for transmitting at
least one output of the at least one user-health test function
related to the at least one advertiser-specified attribute.
86. The computer program product of claim 85, wherein the
signal-bearing medium includes a computer-readable medium.
87. The computer program product of claim 85, wherein the
signal-bearing medium includes a recordable medium.
88. The computer program product of claim 85, wherein the
signal-bearing medium includes a communications medium.
89. A system comprising: a computing device; and instructions that
when executed on the computing device cause the computing device to
(a) specify at least one of a plurality of user-health test
functions responsive to an interaction between a user and at least
one advertiser-specified attribute; and (b) transmit at least one
output of the at least one user-health test function related to the
at least one advertiser-specified attribute.
90. The system of claim 89 wherein the computing device comprises:
one or more of a personal digital assistant (PDA), a personal
entertainment device, a mobile phone, a laptop computer, a tablet
personal computer, a networked computer, a computing system
comprised of a cluster of processors, a computing system comprised
of a cluster of servers, a workstation computer, and/or a desktop
computer.
91. The system of claim 89 wherein the computing device is operable
to specify at least one of a plurality of user-health test
functions responsive to an interaction between a user and at least
one advertiser-specified attribute from at least one memory.
92. The system of claim 89 wherein the computing device is operable
to transmit at least one output of the at least one user-health
test function related to the at least one advertiser-specified
attribute from at least one memory.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
11/595,212, filed Nov. 9, 2006 which is a Continuation-in-Part of
application Ser. No. 10/806,775, filed Mar. 22, 2004, now U.S. Pat.
No. 7,127,775 which is a continuation in part of PCT/US04/08578,
filed Mar. 19, 2004 and claims benefit of application Ser. No.
60/456,413, filed Mar. 20, 2003 and application Ser. No.
60/554,702, filed Mar. 20, 2004.
BACKGROUND OF INVENTION
[0002] The present invention is directed to a fan array fan section
utilized in an air-handling system.
[0003] Air-handling systems (also referred to as an air handler)
have traditionally been used to condition buildings or rooms
(hereinafter referred to as "structures"). An air-handling system
is defined as a structure that includes components designed to work
together in order to condition air as part of the primary system
for ventilation of structures. The air-handling system may contain
components such as cooling coils, heating coils, filters,
humidifiers, fans, sound attenuators, controls, and other devices
functioning to meet the needs of the structures. The air-handling
system may be manufactured in a factory and brought to the
structure to be installed or it may be built on site using the
necessary devices to meet the functioning needs of the structure.
The air-handling compartment 102 of the air-handling system
includes the inlet plenum 112 prior to the fan inlet cone 104 and
the discharge plenum 110. Within the air-handling compartment 102
is situated the fan unit 100 (shown in FIGS. 1 and 2 as an inlet
cone 104, a fan 106, and a motor 108), fan frame, and any
appurtenance associated with the function of the fan (e.g. dampers,
controls, settling means, and associated cabinetry). Within the fan
106 is a fan wheel (not shown) having at least one blade. The fan
wheel has a fan wheel diameter that is measured from one side of
the outer periphery of the fan wheel to the opposite side of the
outer periphery of the fan wheel. The dimensions of the handling
compartment 102 such as height, width, and airway length are
determined by consulting fan manufacturers data for the type of fan
selected.
[0004] FIG. 1 shows an exemplary prior art air-handling system
having a single fan unit 100 housed in an air-handling compartment
102. For exemplary purposes, the fan unit 100 is shown having an
inlet cone 104, a fan 106, and a motor 108. Larger structures,
structures requiring greater air volume, or structures requiring
higher or lower temperatures have generally needed a larger fan
unit 100 and a generally correspondingly larger air-handling
compartment 102.
[0005] As shown in FIG. 1, an air-handling compartment 102 is
substantially divided into a discharge plenum 110 and an inlet
plenum 112. The combined discharge plenum 110 and the inlet plenum
112 can be referred to as the airway path 120. The fan unit 100 may
be situated in the discharge plenum 110 as shown), the inlet plenum
112, or partially within the inlet plenum 112 and partially within
the discharge plenum 110. The portion of the airway path 120 in
which the fan unit 100 is positioned may be generically referred to
as the "fan section" (indicated by reference numeral 114). The size
of the inlet cone 104, the size of the fan 106, the size the motor
108, and the size of the fan frame (not shown) at least partially
determine the length of the airway path 120. Filter banks 122
and/or cooling coils (not shown) may be added to the system either
upstream or downstream of the fan units 100.
[0006] For example, a first exemplary structure requiring 50,000
cubic feet per minute of air flow at six (6) inches water gage
pressure would generally require a prior art air-handling
compartment 102 large enough to house a 55 inch impeller, a 100
horsepower motor, and supporting framework. The prior art
air-handling compartment 102, in turn would be approximately 92
inches high by 114 to 147 inches wide and 106 to 112 inches long.
The minimum length of the air-handling compartment 102 and/or
airway path 120 would be dictated by published manufacturers data
for a given fan type, motor size, and application. Prior art
cabinet sizing guides show exemplary rules for configuring an
air-handling compartment 102. These rules are based on
optimization, regulations, and experimentation.
[0007] For example, a second exemplary structure includes a
recirculation air handler used in semiconductor and pharmaceutical
clean rooms requiring 26,000 cubic feet per minute at two (2)
inches water gage pressure. This structure would generally require
a prior art air-handling system with a air-handling compartment 102
large enough to house a 44 inch impeller, a 25 horsepower motor,
and supporting framework. The prior art air-handling compartment
102, in turn would be approximately 78 inches high by 99 inches
wide and 94 to 100 inches long. The minimum length of the
air-handling compartment 102 and/or airway path 120 would be
dictated by published manufacturers data for a given fan type,
motor size and application. Prior art cabinet sizing guides show
exemplary rules for configuring an air-handling compartment 102.
These rules are based on optimization, regulations, and
experimentation.
[0008] These prior art air-handling systems have many problems
including the following exemplary problems:
[0009] Because real estate (e.g. structure space) is extremely
expensive, the larger size of the air-handling compartment 102 is
extremely undesirable.
[0010] The single fan units 100 are expensive to produce and are
generally custom produced for each job.
[0011] Single fan units 100 are expensive to operate.
[0012] Single fan units 100 are inefficient in that they only have
optimal or peak efficiency over a small portion of their operating
range.
[0013] If a single fan unit 100 breaks down, there is no air
conditioning at all.
[0014] The low frequency sound of the large fan unit 100 is hard to
attenuate.
[0015] The high mass and turbulence of the large fan unit 100 can
cause undesirable vibration.
[0016] Height restrictions have necessitated the use of
air-handling systems built with two fan units 100 arranged
horizontally adjacent to each other. It should be noted, however,
that a good engineering practice is to design air handler cabinets
and discharge plenums 110 to be symmetrical to facilitate more
uniform air flow across the width and height of the cabinet. Twin
fan units 100 have been utilized where there is a height
restriction and the unit is designed with a high aspect ratio to
accommodate the desired flow rate. As shown in the Greenheck
"Installation Operating and Maintenance Manual," if side-by-side
installation was contemplated, there were specific instructions to
arrange the fans such that there was at least one fan wheel
diameter spacing between the fan wheels and at least one-half a fan
wheel diameter between the fan and the walls or ceilings. The
Greenheck reference even specifically states that arrangements
"with less spacing will experience performance losses." Normally,
the air-handling system and air-handling compartment 102 are
designed for a uniform velocity gradient of 500 feet per minute
velocity in the direction of air flow. The two fan unit 100
air-handling systems, however, still substantially suffered from
the problems of the single unit embodiments. There was no
recognition of advantages by increasing the number of fan units 100
from one to two. Further, the two fan unit 100 section exhibits a
non-uniform velocity gradient in the region following the fan unit
100 that creates uneven air flow across filters, coils, and sound
attenuators.
[0017] It should be noted that electrical devices have taken
advantage of multiple fan cooling systems. For example, U.S. Pat.
No. 6,414,845 to Bonet uses a multiple-fan modular cooling
component for installation in multiple component-bay electronic
devices. Although some of the advantages realized in the Bonet
system would be realized in the present system, there are
significant differences. For example, the Bonet system is designed
to facilitate electronic component cooling by directing the output
from each fan to a specific device or area. The Bonet system would
not work to direct air flow to all devices in the direction of
general air flow. Other patents such as U.S. Pat. No. 4,767,262 to
Simon and U.S. Pat. No. 6,388,880 to El-Ghobashy et al. teach fan
arrays for use with electronics.
[0018] Even in the computer and machine industries, however,
operating fans in parallel is taught against as not providing the
desired results except in low system resistance situations where
fans operate in near free delivery. For example, Sunon Group has a
web page in which they show two axial fans operating in parallel,
but specifically state that if "the parallel fans are applied to
the higher system resistance that [an] enclosure has, . . . less
increase in flow results with parallel fan operation." Similar
examples of teaching against using fans in parallel are found in an
article accessible from HighBeam Research's library
(http://stati.highbeam.com) and an article by Ian McLeod accessible
at (http://www.papstplc.com).
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention is directed to a fan array fan section
in an air-handling system that includes a plurality of fan units
arranged in a fan array and positioned within an air-handling
compartment. One preferred embodiment may include an array
controller programmed to operate the plurality of fan units at peak
efficiency. The plurality of fan units may be arranged in a true
array configuration, a spaced pattern array configuration, a
checker board array configuration, rows slightly offset array
configuration, columns slightly offset array configuration, or a
staggered array configuration.
[0020] The foregoing and other objectives, features, and advantages
of the invention will be more readily understood upon consideration
of the following detailed description of the invention, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] FIG. 1 is a side view of an exemplary prior art air-handling
system having a single large fan unit within an air-handling
compartment.
[0022] FIG. 2 is a perspective view of an exemplary prior art large
fan unit.
[0023] FIG. 3 is a side view of an exemplary fan array fan section
in an air-handling system of the present invention having a
plurality of small fan units within an air-handling
compartment.
[0024] FIG. 4 is a plan or elevation view of a 4.times.6 exemplary
fan array fan section in an air-handling system of the present
invention having a plurality of small fan units within an
air-handling compartment.
[0025] FIG. 5 is a plan or elevation view of a 5.times.5 exemplary
fan array fan section in an air-handling system of the present
invention having a plurality of small fan units within an
air-handling compartment.
[0026] FIG. 6 is a plan or elevation view of a 3.times.4 exemplary
fan array fan section in an air-handling system of the present
invention having a plurality of small fan units within an
air-handling compartment.
[0027] FIG. 7 is a plan or elevation view of a 3.times.3 exemplary
fan array fan section in an air-handling system of the present
invention having a plurality of small fan units within an
air-handling compartment.
[0028] FIG. 8 is a plan or elevation view of a 3.times.1 exemplary
fan array fan section in an air-handling system of the present
invention having a plurality of small fan units within an
air-handling compartment.
[0029] FIG. 9 is a plan or elevation view of an alternative
exemplary fan array fan section in an air-handling system of the
present invention in which a plurality of small fan units are
arranged in a spaced pattern array within an air-handling
compartment.
[0030] FIG. 10 is a plan or elevation view of an alternative
exemplary fan array fan section in an air-handling system of the
present invention in which a plurality of small fan units are
arranged in a checker board array within an air-handling
compartment.
[0031] FIG. 11 is a plan or elevation view of an alternative
exemplary fan array fan section in an air-handling system of the
present invention in which a plurality of small fan units are
arranged in rows slightly offset array within an air-handling
compartment.
[0032] FIG. 12 is a plan or elevation view of an alternative
exemplary fan array fan section in an air-handling system of the
present invention in which a plurality of small fan units are
arranged in columns slightly offset array within an air-handling
compartment.
[0033] FIG. 13 is a plan or elevation view of a 5.times.5 exemplary
fan array fan section in an air-handling system of the present
invention running at 52% capacity by turning a portion of the fans
on and a portion of the fans off.
[0034] FIG. 14 is a plan or elevation view of a 5.times.5 exemplary
fan array fan section in an air-handling system of the present
invention running at 32% capacity by turning a portion of the fans
on and a portion of the fans off.
[0035] FIG. 15 is a side view of an alternative exemplary fan array
fan section in an air-handling system of the present invention
having a plurality of staggered small fan units within an
air-handling compartment.
[0036] FIG. 16 is a perspective view of an exemplary fan array
using a grid system into which fan units are mounted.
[0037] FIG. 17 is a perspective view of an exemplary fan array
using a grid system or modular units each of which includes a fan
units mounted within its own fan unit chamber.
[0038] FIG. 18 is a perspective view of an exemplary array of
dampeners that may be positioned either in front of or behind the
fan units.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention is directed to a fan array fan section
in an air-handling system. As shown in FIGS. 3-12, the fan array
fan section in the air-handling system uses a plurality of
individual single fan units 200. In one preferred embodiment, the
fan units 200 are arranged in a true array (FIGS. 4-8), but
alternative embodiments may include, for example, alternative
arrangements such as in a spaced pattern (FIG. 9), a checker board
(FIG. 10), rows slightly offset (FIG. 11), or columns slightly
offset (FIG. 12). As the present invention could be implemented
with true arrays and/or alternative arrays, the term "array" is
meant to be comprehensive.
[0040] The fan units 200 in the fan array of the present invention
may be spaced as little as 20% of a fan wheel diameter. Optimum
operating conditions for a closely arranged array may be found at
distances as low as 30% to 60% of a fan wheel diameter. By closely
spacing the fan units 200, more air may be moved in a smaller
space. For example, if the fan wheels of the fan units 200 have a
20 inch fan wheel diameter, only a 4 inch space (20%) is needed
between the outer periphery of one fan wheel and the outer
periphery of the adjacent fan wheel (or a 2 inch space between the
outer periphery of a fan wheel and an the adjacent wall or
ceiling).
[0041] By using smaller fan units 200 it is possible to support the
fan units 200 with less intrusive structure (fan frame). This can
be compared to the large fan frame that supports prior art fan
units 100 and functions as a base. This large fan frame must be
large and sturdy enough to support the entire weight of the prior
art fan units 100. Because of their size and position, the known
fan frames cause interference with air flow. In the preferred
embodiment, therefore, the fan units 200 of the fan array may be
supported by a frame that supports the motors 108 with a minimum
restriction to air flow.
[0042] As mentioned in the Background, others have tried using
side-by-side installation of two fan units 100 arranged
horizontally adjacent to each other within an air-handling system.
As is also mentioned in the Background, fan arrays have been used
in electronic and computer assemblies. However, in the air-handling
system industry, it has always been held that there must be
significant spacing between the horizontally arranged fan wheels
and that arrangements with less spacing will experience performance
losses. A single large fan moves all the air in a cabinet. Using
two of the same or slightly smaller fans caused the air produced by
one fan to interfere with the air produced by the other fan. To
alleviate the interference problem, the fans had to be spaced
within certain guidelines--generally providing a clear space
between the fans of a distance of at least one wheel diameter (and
a half a wheel diameter to an adjacent wall). Applying this logic,
it would not have made sense to add more fans. And even if
additional fans had been added, the spacing would have continued to
be at least one wheel diameter between fans. Further, in the
air-handling system industry, vertically stacking fan units would
have been unthinkable because the means for securing the fan units
would not have been conducive to such stacking (they are designed
to be positioned on the floor only).
[0043] It should be noted that the plenum fan is the preferred fan
unit 200 of the present invention. In particular, the APF-121,
APF-141, APF-161, and APF-181 plenum fans (particularly the fan
wheel and the fan cone) produced by Twin City Fan Companies, Ltd.
of Minneapolis, Minn., U.S. has been found to work well. The reason
that plenum fans work best is that they do not produce points of
high velocity such as those produced by axial fans and housed
centrifugal fans and large plenum fans. Alternative embodiments use
known fan units or fan units yet to be developed that will not
produce high velocity gradients in the direction of air flow. Still
other embodiments, albeit less efficient, use fan units such as
axial fans and/or centrifugal housed fans that have points of high
velocity in the direction of air flow.
[0044] In the preferred embodiment, each of the fan units 200 in
the fan array fan section in the air-handling system is controlled
by an array controller 300 (FIGS. 13 and 14). In one preferred
embodiment, the array controller 300 may be programmed to operate
the fan units 200 at peak efficiency. In this peak efficiency
embodiment, rather than running all of the fan units 200 at a
reduced efficiency, the array controller 300 turns off certain fan
units 200 and runs the remaining fan units 200 at peak efficiency.
In an alternative embodiment, the fan units 200 could all run at
the same power level (e.g. efficiency and/or flow rate) of
operation.
[0045] Another advantage of the present invention is that the array
controller 300 (which may be a variable frequency drive (VFD)) used
for controlling fan speed and thus flow rate and pressure, could be
sized for the actual brake horsepower of the fan array fan section
in the air-handling system. Since efficiency of the fan wall array
can be optimized over a wide range of flow rates and pressures, the
actual operating power consumed by the fan array is substantially
less than the actual operating power consumed by the comparable
prior art air-handling systems and the array controller's power
could be reduced accordingly. The array controller 300 could be
sized to the actual power consumption of the fan array where as the
controller (which may have been a variable frequency drive) in a
traditional design would be sized to the maximum nameplate rating
of the motor per Electrical Code requirements. An example of a
prior art fan design supplying 50,000 cubic feet per minute of air
at 2.5 inches pressure, would require a 50 horsepower motor and 50
horsepower controller. The new invention will preferably use an
array of fourteen 2 horsepower motors and a 30 horsepower array
controller 300.
[0046] This invention solves many of the problems of the prior art
air-handling systems including, but not limited to real estate,
reduced production costs, reduced operating expenses, increased
efficiency, improved air flow uniformity, redundancy, sound
attenuation advantages, and reduced vibration.
Controllability
[0047] As mentioned, preferably each of the fan units 200 in the
fan array fan section in the air-handling system is controlled by
an array controller 300 (FIGS. 13 and 14) that may be programmed to
operate the fan units 200 at peak efficiency. In this peak
efficiency embodiment, rather than running all of the fan units 200
at a reduced efficiency, the array controller 300 is able to turn
off certain fan units 200 and run the remaining fan units 200 at
peak efficiency. Preferably, the array controller 300 is able to
control fan units 200 individually, in predetermined groupings,
and/or as a group as a whole.
[0048] For example, in the 5.times.5 fan array such as that shown
in FIGS. 5, 13, and 14, a person desiring to control the array may
select desired air volume, a level of air flow, a pattern of air
flow, and/or how many fan units 200 to operate. Turning first to
air volume, each fan unit 200 in a 5.times.5 array contributes 4%
of the total air. In variable air volume systems, which is what
most structures have, only the number of fan units 200 required to
meet the demand would operate. A control system (that may include
the array controller 300) would be used to take fan units 200 on
line (an "ON" fan unit 200) and off line (an "OFF" fan unit 200)
individually. This ability to turn fan units 200 on and off could
effectively eliminate the need for a variable frequency drive.
Similarly, each fan unit 200 in a 5.times.5 array uses 4% of the
total power and produces 4% of the level of air flow. Using a
control system to take fan units 200 on line and off line allows a
user to control power usage and/or air flow. The pattern of air
flow can also be controlled if that would be desirable. For
example, depending on the system it is possible to create a pattern
of air flow only around the edges of a cabinet or air only at the
top. Finally, individual fan units 200 may be taken on line and off
line. This controllability may be advantageous if one or more fan
units 200 are not working properly, need to be maintained (e.g.
needs general service), and/or need to be replaced. The problematic
individual fan units 200 may be taken off line while the remainder
of the system remains fully functional. Once the individual fan
units 200 are ready for use, they may be brought back on line.
[0049] A further advantage to taking fan units 200 on and off line
occurs when building or structure control systems require low
volumes of air at relatively high pressures. In this case, the fan
units 200 could be modulated to produce a stable operating point
and eliminate the surge effects that sometimes plague structure
owners and maintenance staff. The surge effect is where the system
pressure is too high for the fan speed at a given volume and the
fan unit 200 has a tendency to go into stall.
[0050] Examples of controllability are shown in FIGS. 13 and 14. In
the fan array fan section in the air-handling system shown in FIG.
13, the array controller 300 alternates "ON" fan units 200 and
"OFF" fan units 200 in a first exemplary pattern as shown so that
the entire system is set to operate at 52% of the maximum rated air
flow but only consumes 32% of full rated power. These numbers are
based on exemplary typical fan operations in a structure. FIG. 14
shows the fan array fan section in the air-handling system set to
operate at 32% of the maximum rated air flow but only consumes 17%
of full rated power. These numbers are based on exemplary typical
fan operations in a structure. In this embodiment, the array
controller 300 creates a second exemplary pattern of "OFF" fan
units 200 and "ON" fan units 200 as shown.
Real Estate
[0051] The fan array fan section in the air-handling section 220 of
the present invention preferably uses (60% to 80%) less real estate
than prior art discharge plenums 120 (with the hundred series
number being prior art as shown in FIG. 1 and the two hundred
series number being the present invention as shown in FIG. 3) in
air-handling systems. Comparing the prior art (FIG. 1) and the
present invention (FIG. 3) shows a graphical representation of this
shortening of the airway path 120, 220. There are many reasons that
using multiple smaller fan units 200 can reduce the length of the
airway path 120, 220. For example, reducing the size of the fan
unit 100, 200 and motor 108, 208 reduces the length of the
discharge plenum 110, 210. Similarly, reducing the size of the
inlet cone 104, 204 reduces the length of the inlet plenum 112,
212. The length of the discharge plenum 110, 210 can also be
reduced because air from the fan array fan section in the
air-handling system of the present invention is substantially
uniform whereas the prior art air-handling system has points of
higher air velocity and needs time and space to mix so that the
flow is uniform by the time it exits the air-handling compartment
102, 202. (This can also be described as the higher static
efficiency in that the present invention eliminates the need for
settling means downstream from the discharge of a prior art fan
system because there is little or no need to transition from high
velocity to low velocity.) The fan array fan section in the
air-handling system takes in air from the inlet plenum 212 more
evenly and efficiently than the prior art air-handling system so
that the length of the inlet plenum 112, 212 may be reduced.
[0052] For purposes of comparison, the first exemplary structure
set forth in the Background of the Invention (a structure requiring
50,000 cubic feet per minute of air flow at a pressure of six (6)
inches water gage) will be used. Using the first exemplary
structure, an exemplary embodiment of the present invention could
be served by a nominal discharge plenum 210 of 89 inches high by
160 inches wide and 30 to 36 inches long (as compared to 106 to 112
inches long in the prior art embodiments). The discharge plenum 210
would include a 3.times.4 fan array fan section in the air-handling
system such as the one shown in FIG. 6) having 12 fan units 200.
The space required for each exemplary fan unit 200 would be a
rectangular cube of approximately 24 to 30 inches on a side
depending on the array configuration. The airway path 220 is 42 to
48 inches (as compared to 88 to 139 inches in the prior art
embodiments).
[0053] For purposes of comparison, the second exemplary structure
set forth in the Background of the Invention (a structure requiring
26,000 cubic feet per minute of air flow at a pressure of two (2)
inches water gage) will be used. Using the second exemplary
structure, an exemplary embodiment of the present invention could
be served by a nominal discharge plenum 210 of 84 inches high by 84
inches wide, and and 30 to 36 inches long (as compared to 94 to 100
inches long in the prior art embodiments). The discharge plenum
would include a 3.times.3 fan array fan section in the air-handling
system (such as the one shown in FIG. 7) having 9 fan units 200.
The space required for each exemplary fan unit 200 would be a
rectangular cube of approximately 24 to 30 inches on a side
depending on the array configuration. The airway path 220 is 42 to
48 inches (as compared to 71 to 95 inches in the prior art
embodiments).
Reduced Production Costs
[0054] It is generally more cost effective to build the fan array
fan section in the air-handling system of the present invention as
compared to the single fan unit 100 used in prior art air-handling
systems. Part of this cost savings may be due to the fact that
individual fan units 200 of the fan array can be mass-produced.
Part of this cost savings may be due to the fact that it is less
expensive to manufacture smaller fan units 200. Whereas the prior
art single fan units 100 were generally custom built for the
particular purpose, the present invention could be implemented on a
single type of fan unit 200. In alternative embodiments, there
might be several fan units 200 having different sizes and/or powers
(both input and output). The different fan units 200 could be used
in a single air-handling system or each air-handling system would
have only one type of fan unit 200. Even when the smaller fan units
200 are custom made, the cost of producing multiple fan units 200
for a particular project is almost always less that the cost of
producing a single large prior art fan unit 100 for the same
project. This may be because of the difficulties of producing the
larger components and/or the cost of obtaining the larger
components necessary for the single large prior art fan unit 100.
This cost savings also extends to the cost of producing a smaller
air-handling compartment 202.
[0055] In one preferred embodiment of the invention, the fan units
200 are modular such that the system is "plug and play." Such
modular units may be implemented by including structure for
interlocking on the exterior of the fan units 200 themselves.
Alternatively, such modular units may be implemented by using
separate structure for interlocking the fan units 200. In still
another alternative embodiment, such modular units may be
implemented by using a grid system into which the fan units 200 may
be placed.
Reduced Operating Expenses
[0056] The fan array fan section in the air-handling system of the
present invention preferably are less expensive to operate than
prior art air-handling systems because of greater flexibility of
control and fine tuning to the operating requirements of the
structure. Also, by using smaller higher speed fan units 200 that
require less low frequency noise control and less static resistance
to flow.
Increased Efficiency
[0057] The fan array fan section in the air-handling system of the
present invention preferably is more efficient than prior art
air-handling systems because each small fan unit 200 can run at
peak efficiency. The system could turn individual fan units 200 on
and off to prevent inefficient use of particular fan units 200. It
should be noted that an array controller 300 could be used to
control the fan units 200. As set forth above, the array controller
300 turns off certain fan units 200 and runs the remaining fan
units 200 at peak efficiency.
Redundancy
[0058] Multiple fan units 200 add to the redundancy of the system.
If a single fan unit 200 breaks down, there will still be cooling.
The array controller 300 may take disabled fan units 200 into
consideration such that there is no noticeable depreciation in
cooling or air flow rate. This feature may also be useful during
maintenance as the array controller 300 may turn off fan units 200
that are to be maintained offline with no noticeable depreciation
in cooling or air flow rate.
Sound Attenuation Advantages
[0059] The high frequency sound of the small fan units 200 is
easier to attenuate than the low frequency sound of the large fan
unit. Because the fan wall has less low frequency sound energy,
shorter less costly sound traps are needed to attenuate the higher
frequency sound produced by the plurality of small fan units 200
than the low frequency sound produced by the single large fan unit
100. The plurality of fan units 200 will each operate in a manner
such that acoustic waves from each unit will interact to cancel
sound at certain frequencies thus creating a quieter operating unit
than prior art systems.
Reduced Vibration
[0060] The multiple fan units 200 of the present invention have
smaller wheels with lower mass and create less force due to
residual unbalance thus causing less vibration than the large fan
unit. The overall vibration of multiple fan units 200 will transmit
less energy to a structure since individual fans will tend to
cancel each other due to slight differences in phase. Each fan unit
200 of the multiple fan units 200 manage a smaller percentage of
the total air handling requirement and thus produce less turbulence
in the air stream and substantially less vibration.
Alternative Embodiments
[0061] As mentioned, in one preferred embodiment of the invention,
the fan units 200 are modular such that the system is "plug and
play." Such modular units may be implemented by including structure
for interlocking on the exterior of the fan units 200 themselves.
Alternatively, such modular units may be implemented by using
separate structure for interlocking the fan units 200. In still
another alternative embodiment, such modular units may be
implemented by using a grid system into which the fan units 200 may
be placed.
[0062] FIG. 16 shows an embodiment using an exemplary grid system
230 into which the fan units 200 may be placed. In this embodiment
the grid may be positioned and/or built within the air-handling
compartment 202. The fan units 200 may then be positioned into the
grid openings. One advantage of this configuration is that
individual fan units 200 may be easily removed, maintained, and/or
replaced. This embodiment uses an exemplary unique motor mount 232
that supports the motor 208 without interfering with air flow
therearound. As shown, this exemplary motor mount 232 has a
plurality of arms that mount around the fan inlet cone 204. It
should be noted that the dimensions of the grid are meant to be
exemplary. The grid may be constructed taking into consideration
that the fan units 200 in the present invention may be spaced with
as little as 20% of a fan wheel diameter between the fan units
200.
[0063] FIG. 17 shows an embodiment using either a grid system or
modular units 240 using separate structure (not shown) for
interlocking the fan units 200. In this exemplary embodiment, each
of the fan units 200 are mounted on a more traditional motor mount
242 within its own fan unit chamber 244. In one preferred
embodiment, the fan unit 200 and motor mount 242 are preferably
suspended within their own fan unit chamber 244 such that there is
an air relief passage 246 therebelow. This air relieve passage 246
tends to improve air flow around the fan units 200.
[0064] The fan unit chambers 244 shown in FIG. 17 may include one
ore more interior surface made from or lined with an acoustically
absorptive material or "insulation surface" 248. Going against
conventional industry wisdom that surfaces cannot be placed in
close proximity with the fan units 200, the present invention
places one or more insulation surfaces 248 at least partially
around each fan unit 200 without disrupting air flow. The
insulation surfaces 248 may include one or more of the sides, top,
bottom, front, or back. Exemplary types of insulation include, but
are not limited to traditional insulation board (such as that made
from inorganic glass fibers (fiberglass) alone or with a
factory-applied foil-scrim-kraft (FSK) facing or a factory-applied
all service jacket (ASJ)) or alternative insulation such as open
cell foam such as that disclosed in U.S. patent application Ser.
No. 10/606,435, which is assigned to the assignee of the present
invention, and which the disclosure of which is hereby incorporated
by reference herein. Together, the insulation surfaces 248 on the
fan unit chambers 244 tend to function as a coplanar silencer. Some
of the benefits of using the coplanar silencer include (1) no added
airway length for splitters, (2) no pressure drop, and/or (3)
relatively low cost. The acoustic advantages of this and other
embodiments make the present invention ideal for use in concert
halls, lecture halls, performing arts centers, libraries,
hospitals, and other applications that are acoustically
sensitive.
[0065] Although FIG. 17 shows the discharge plenum 210 positioned
within the fan unit chambers 244, alternative embodiments of fan
unit chambers 244 could enclose the inlet plenum 212, or at least
partially enclose both the inlet plenum 212 and the discharge
plenum 210. Still other alternative embodiments of fan unit
chambers 244 may have grid or wire surfaces (that increase the
safety of the present invention) or be open (that would reduce
costs).
[0066] FIG. 18 shows an array of dampeners 250 that may be
positioned either in front of or behind the fan units 200 to at
least partially prevent back drafts. In the shown exemplary
embodiment, the dampeners 250 include a plurality of plates, each
plate positioned on its own pivot. In the shown exemplary
embodiment, the plurality of plates slightly overlap each other.
The shown embodiment is constructed such that when air is flowing
through the fan units 200, the plates are in the open position and
when the air stops, gravity pulls the plates into the closed
position. Preferably, each of the dampeners 250 operates
independently such that if some of the fan units 200 are ON and
some of the fan units 200 are OFF, the dampeners 250 can open or
close accordingly. Although shown as a simple mechanical
embodiment, alternative embodiments could include structure that is
controlled electronically and/or remotely from the dampeners
250.
[0067] It should be noted that FIG. 4 shows a 4.times.6 fan array
fan section in the air-handling system having twenty-four fan units
200, FIG. 5 shows a 5.times.5 fan array fan section in the
air-handling system having twenty-five fan units 200, FIG. 6 shows
a 3.times.4 fan array fan section in the air-handling system having
twelve fan units 200, FIG. 7 shows a 3.times.3 fan array fan
section in the air-handling system having nine fan units 200, and
FIG. 8 shows a 3.times.1 fan array fan section in the air-handling
system having three fan units 200. It should be noted that the
array may be of any size or dimension of more than two fan units
200. It should be noted that although the fan units 200 may be
arranged in a single plane (as shown in FIG. 3), an alternative
array configuration could contain a plurality of fan units 200 that
are arranged in a staggered configuration (as shown in FIG. 15) in
multiple planes. It should be noted that cooling coils (not shown)
could be added to the system either upstream or downstream of the
fan units 200. It should be noted that, although shown upstream
from the fan units 200, the filter bank 122, 222 could be
downstream.
[0068] It should be noted that an alternative embodiment would use
a horizontally arranged fan array. In other words, the embodiments
shown in FIGS. 3-15 could be used horizontally or vertically or in
any direction perpendicular to the direction of air flow. For
example, if a vertical portion of air duct is functioning as the
air-handling compartment 202, the fan array may be arranged
horizontally. This embodiment would be particularly practical in an
air handling compartment for a return air shaft.
[0069] It should be noted that the fan section 214 may be any
portion of the airway path 220 in which the fan units 200 are
positioned. For example, the fan units 200 may be situated in the
discharge plenum 210 (as shown), the inlet plenum 212, or partially
within the inlet plenum 212 and partially within the discharge
plenum 210. It should also be noted that the air-handling
compartment 202 may be a section of air duct.
[0070] The terms and expressions that have been employed in the
foregoing specification are used as terms of description and not of
limitation, and are not intended to exclude equivalents of the
features shown and described or portions of them. The scope of the
invention is defined and limited only by the claims that
follow.
* * * * *
References